2005 LEXUS ES300 Repair Manual

D03860
C56360
Underdrive
Clutch
Return
Spring
Underdrive
Clutch Drum
C56359
Clutch
Balancer
Underdrive
Clutch Drum
D03703
SST
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the underdrive clutch piston with ATF, install it to the
underdrive clutch piston drum.
NOTICE:

Be careful not to damage the O-ring.

Be careful not to damage the lip seal of the piston.
12. INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Install the return spring to the underdrive clutch drum.
NOTICE:
Installing the spring sub- assembly, check all of the
springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the underdrive clutch drum.
NOTICE:
Be careful not to damage the lip seal of the clutch balancer.
(d) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09350-32014 (09351-32070)
(e) Using a snap ring expander, install the snap ring to the un-
derdrive clutch drum.
(f) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:

Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

D25592
StopperStopper
D26431
Disc
Flange
Plate
D03701
D26429
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- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Set the end gap of the snap ring in the underdrive clutch
drum shown in the illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stopper.
13. INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Apply the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the underdrive
clutch drum.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
14. INSTALL UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, install the underdrive clutch flange
No.2 hole snap ring.
(b) Check that the end gap of snap ring is not aligned with one
of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
15. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Set a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch piston stroke while apply-
ing and releasing compressed air (392 kPa, 4.0 kgf/cm
2,
57 psi).
Park clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the pack clearance is not within standard, select another
flange.
HINT:
There are 5 flanges in different thickness.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)43.1 (0.122)
23.2 (0.126)53.3 (0.130)
33.4 (0.134)--

4006K-03
D25593
SST Underdrive
Planetary Gear
D25594
SST
D03686
SST
D03687
Underdrive
Planetary Gear
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40-99
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE PLANETARY GEAR ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST, fix the underdrive planetary gear assy.
SST 09387-00050
(b) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.50 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
2. REMOVE FRONT PLANETARY GEAR NUT
(a) Using SST, loosen the staked part of the lock nut.
SST 09930- 00010 (09931- 00010, 09931- 00020),
09387-00050
(b) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.

D25609
Underdrive
Planetary Gear
D03689
SST
HoldTurn
D26437
SST
D03691
SST SST
Hold
Turn
D03826
Snap Ring
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ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Using a socket wrench, remove the lock nut.
3. REMOVE CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using SST, remove the cylindrical roller bearing race in-
ner.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00320), 09950-40011 (09957-04010)
4. REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Using SST and a press, remove the differential drive pin-
ion, parking lock gear, counter driven gear with under-
drive planetary ring gear and front tapered roller bearing.
SST 09950-60010 (09951-00320), 09387-00050
(b) Clamp the underdrive planetary gear in soft jaw vise.
(c) Using SST, remove the rear tapered roller bearing form
the underdrive planetary gear.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00320), 09950-40011 (09957-04010)
5. REMOVE UNDERDRIVE PLANETARY RING GEAR
(a) Using a snap ring pliers, remove the snap ring.

D03827Counter Driven Gear
Underdrive
Planetary Ring Gear
D08112Snap Ring
D08113
D08114
SST
SST
D03827Counter Driven Gear
Underdrive
Planetary Ring Gear
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40-101
125 Author
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Remove the underdrive planetary ring gear from the
counter driven gear.
6. INSTALL UNDERDRIVE PLANETARY RING GEAR
(a) Install a new snap ring to the outer race of the tapered roll-
er bearing.
HINT:
When replacing the bearing, also replace the counter driven
gear with a new one.
(b) Using a piston ring compressor, squeeze the snap ring.
(c) Using SST and a press, press in the outer race of the ta-
pered roller bearing.
SST 09950- 60020 (09951- 00890), 09950- 70010
(09951-07100)
NOTICE:
Be sure not to damage on the snap ring during the outer
race installation.
(d) Install the underdrive planetary ring gear to the counter
driven gear.

D08115
Snap Ring
D26435
SST
D08117
D26436
SST
D26433
SST
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ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using a snap ring pliers, install the snap ring.
7. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Using a press, press the rear tapered roller bearing to the
underdrive planetary gear.
SST 09502- 12010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100), 09316-20011
NOTICE:
Press the bearing until it becomes flat at the bottom.
(b) Install the counter driven gear with planetary ring gear to
the underdrive planetary gear.
(c) Using SST and a press, press in the front tapered roller
bearing.
SST 09502- 12010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100), 09316-20011
NOTICE:
Press the counter driven gear while rotating it.
(d) Using a press, press in the parking lock gear.
SST 09502- 12010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100), 09316-20011
NOTICE:
Press the counter driven gear while rotating it.

D26434
SST
Differential
Drive Pinion
D26432
SST
D25609
Underdrive
Planetary Gear
D25594
SST Underdrive
Planetary Gear
C56809
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40-103
127 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
8. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using a press, press the differential drive pinion.
SST 09726- 40010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
9. INSTALL CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using a press, press the cylindrical roller bearing race in-
ner.
SST 09506- 35010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
10. INSTALL FRONT PLANETARY GEAR NUT
(a) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(b) Using a socket wrench, install a new lock nut.
Torque: 280 NVm (2,855 kgfVcm, 207 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53
in.).
11. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.5 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(b) Using a pin punch and hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.

4010J-01
C89112
D26442
D26438
D26443
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- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
TRANSMISSION VALVE BODY ASSY (U151E/U151F)
OVERHAUL
1. REMOVE SHIFT SOLENOID VALVE SL3
(a) Remove the bolt and shift solenoid valve SL3 from the
valve body assy.
2. REMOVE LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Remove the shift solenoid valve SLT from the valve body
assy.
3. REMOVE SHIFT SOLENOID VALVE S4
(a) Remove the bolt and shift solenoid valve S4 from the
valve body assy.
4. REMOVE SHIFT SOLENOID VALVE SR
(a) Remove the shift solenoid valve SR from the valve body
assy.
5. REMOVE SHIFT SOLENOID VALVE DSL
(a) Remove the bolt and shift solenoid valve DSL from the
valve body assy.